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PQ-7002-0 ASHOK LEYLAND LIMITED STANDARD SURFACE PROTECTION REQUIREMENTS ` 1.0 2.0 3.0 4.0 5.0 Purpose Scope Component Classification Coating Technologies Testing 5.1 5.2 5.3 General Test Conditions Sampling Test Methods 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10 5.3.11 5.3.12 6.0 7.0 References Coated Surface Appearance Dry Film Thickness Adhesion Resistance to Solvents Resistance to UV Light Alternating with Humidity Resistance to Humidity Surface Flow / DOI Erichsen Cupping




  PQ-7002-0 ASHOK LEYLAND LIMITED   ALS.268.03   STANDARD   Issue No: 03   Date: 11.02.2011   SURFACE PROTECTIONREQUIREMENTS   Sheet: 1 of 27  ` CONTENTS 1.0 Purpose 2 2.0 Scope 2 3.0 Component Classification 3 4.0 Coating Technologies 8 5.0 Testing 5.1 General Test Conditions 17 5.2 Sampling 17 5.3 Test Methods 5.3.1 Coated Surface Appearance 18 5.3.2 Dry Film Thickness 18 5.3.3 Adhesion 18 5.3.4 Resistance to Solvents 19 5.3.5 Resistance to UV Light Alternating with Humidity 20 5.3.6 Resistance to Humidity 22 5.3.7 Surface Flow / DOI 23 5.3.8 Erichsen Cupping Resistance 24 5.3.9 Impact Resistance 25 5.3.10 Acid Resistance 26 5.3.11 Alkali Resistance 26 5.3.12 Water Resistance 27 6.0 Agreement of Inspection 27 7.0 References 27    PQ-7002-0 ASHOK LEYLAND LIMITED   ALS.268.03   STANDARD   Issue No: 03   Date: 11.02.2011   SURFACE PROTECTIONREQUIREMENTS   Sheet: 2 of 27  ` 1. PURPOSE: This standard is to provide comprehensive corrosion protection requirements for all thecomponents that require surface protection to meet the performance and aestheticrequirements.This standard classifies the components based on location, functionality and degree of corrosion protection required.This standard also provides guidelines for acceptance test for different coatingprocesses and indicative processes that can be used for protecting surfaces fromdeteriorating effects of environment (corrosion and weathering). 2. SCOPE: The standard classifies the corrosion protection requirements based on location,functional and aesthetic requirements.The standard is applicable to all bought out components, components manufactured inhouse and surface treated at vendor locations.Scope of this standard includes all metallic parts covered in section 3 of this standard.Special requirements not covered in the standard will be mentioned in the respectivepart drawing.Scope of this standard is to specify corrosion protection requirements and acceptancetest requirements. The standard provides guidelines on possible processes that can meetthe end requirements. The process recommendations outlined in standard are indicativein natureZinc Aluminum Flake (ZAC) coating technology is referenced with the appropriateALS Number.The Coatings used should be free from Hazardous substances and must contain lessthan 0.1% lead (Pb), mercury (Hg), hexavalent chromium (Cr 6+ ), polybrominatedbiphenyls (PBB), and polybrominated diphenylethers (PBDE), and less than 0.01%cadmium (Cd).The process shall be validated by CQE / CQ - TPH for process approval. At the time of production part approval, the AL approved surface coating vendor has to submitdetailed Control plan & other validation reports to CQE / CQ - TPH.  PQ-7002-0 ASHOK LEYLAND LIMITED   ALS.268.03   STANDARD   Issue No: 03   Date: 11.02.2011   SURFACE PROTECTIONREQUIREMENTS   Sheet: 3 of 27  `3. COMPONENT CLASSIFICATION: Based on the position and degree of corrosivity, the components / parts comprising thetruck are classified as under. S.No. Level PositionDegree of corrosionprotection requiredDegree of WeatheringResistance requiredList of Parts1 CLASS ADirectly Exposed& Aestheticallyappealing High (Min 1000h asper ASTM B117) High (Min 250h –Gloss Retention =85%, No Chalking,No film cracking)Cab BIWpanels &Exterior Parts,Loadbody 2 CLASS BInterior parts thatwill be visible tocustomers afteropening of closures. Eg.Glove Box High (Min 800h asper ASTM B117) Low (Min 200h –No Chalking, Nofilm Cracking)Cab InteriorSurface items,Cab Threadedparts &metallic trims 3 *CLASS CDirect Exposure &aesthetically lessappealing Moderate (Min300h as per ASTMB117) Medium  (Min 200h– Gloss Retention =85%, No Chalking,No film cracking)Chassis FSM,UnderbodyParts 4 CLASS DIndirect Exposure& No UVresistancerequirement Moderate  (Min300h) as per ASTMB117  Low (Min 200h –No Chalking, Nofilm Cracking)Pipings,Adaptors,Clamps,Chassis & CabFasteners,Exhaust PipesEngine Parts* - Unless Otherwise Specified, Color of Class C Components: Black to RAL 9005  Individual & Specific Color Requirements if any will be provided in drawing.(eg: Scamic Green for Army Vehicles)The Indicative part list for each of the above class is given here.  PQ-7002-0 ASHOK LEYLAND LIMITED   ALS.268.03   STANDARD   Issue No: 03   Date: 11.02.2011   SURFACE PROTECTIONREQUIREMENTS   Sheet: 4 of 27  ` CLASS A – CAB EXTERIOR PARTS – INDICATIVE PART LIST S.No Description Type1 Cab Exterior Panels / Cab BIW shell Sheet Metal2 Grille Sheet Metal3 Bumper Sheet Metal4 FES Sheet Metal5 Bracket – Pedal Support Sheet Metal6 Pedals Sheet Metal7 Foot Step Sheet Metal8 * Loadbody Sheet MetalPossible Process Recommendations for Class A:1.   Pretreatment followed by Cathodic Electrodeposition (CED) & Topcoat as per4.22.   Pretreatment followed by Autophoretic Coating followed by Powder Topcoat asper 4.43.   * - Pretreatment followed by Painting as per 4.6 – Coating Loadbody Interiorswith Polyurea coating is optional for Superior Abrasion Resistance. CLASS B – CAB INTERIOR & METALLIC TRIM – INDICATIVE LIST S.No Description Type1 Cab Threaded parts Steel2 Front Panel – Instrument Cluster Sheet Metal3 Steering Column4 Steering Mounting U Clamp5 Fog lamp Mounting Bracket6 DAT Cap, Fuel Tank CapPossible Process Recommendations for Class B:1.   Pretreatment followed by Cathodic Electrodeposition (CED) as per 4.12.   Zinc Aluminum Flake Coating (ZAC) as per ALS.268.023.   Pretreatment followed by Autophoretic Coating as per 4.4